Method and apparatus for producing yarn



July 4, 1967 3 s0 3,328,947

METHOD AND APPARATUS FOR PRODUCING YARN Filed July 16, 1965 2 Sheets-Sheet 1 INVENTOR. KIRKLAND H. GIBSON y 4, 1967 K. H. GIBSON 3,328,947

METHOD AND APPARATUS FOR PRODUCING YARN Filed July 16, 1965 2 Sheets-Sheet 2 a l2b Ho lob Ilc INVENTOR. KIRKLAND H. GIBSON ATTORNEYS United States Patent METHOD AND APPARATUS FOR PRODUCING YARN Kirkland H. Gibson, North Kingstown, R.I., assignor to Leesona Corporation, Warwick, R.I., a corporation of Massachusetts Filed July 16, 1965, Ser. No. 472,412 6 Claims. c1. 57-34 The present invention relates to method and apparatus for producing yarn and relates, more particularly, to method and apparatus for producing yarn comprised of textured strands wherein the effective denier of each strand is changed periodically in order to create a unique twisted effect in the yarn.

As used herein the term textured strands refer to strands capable of elongation and which have a measurable denier difference as a result of said elongation. Textured yarn means yarn comprised of multiple strands of textured yarn twisted together.

In textile operations it is common to twist several strands together to produce a yarn exhibiting desired, preselected characteristics. For example, it is known to twist several textured strands of different colors together to produce a textured yarn uniformly displaying the variety of colors of the strands in any given section along the yarn. Such variegated yarn may be woven, knitted, tuffted or braided subsequently into a fabric, rug or the like having a mottled appearance. These mottled end products are not only highly acceptable for their aesthetic appearance but also admit of the very practical quality of masking or obscuring dirt, stains and other spots tending to soil the fabric.

In the past it has been found that when several different color textured strands were twisted together on the usual ring twister frame one of the strands would frequently dominate the coloring along certain linear sections of the twisted yarn. This resulted from the fact that some one strand of the several twisted together would be of greater denier than the other strands. Hence, since the strand of the greatest denier obviously occupies more space than the companion strands it dominates the visual color makeup of that section of the yarn strand. This condition has the obvious effect of destroying the uniformly mottled or variegated appearance of the yarn throughout its full length. Equally important, when the yarn so produced is woven into a fabric, rug or the like the end product does not appear uniformly mottled. Rather, the product exhibits bands, striations or patches of one solid color in places, interspersed with areas of the mottled weave. This patterning, i.e., areas of different solid colors interspersed with areas of mottled appearance in the woven fabric, produces a commercially unsatisfactory product.

As already suggested, the conditions leading to the domination of some one strand over the companion stands in the yarn is related to the relative deniers of the several strands. As already pointed out, the yarn of the heaviest denier will occupy the greatest space in any given section along a length of yarn. Hence, the yarn of the heaviest denier will dominate the visual color scheme at that section. Seemingly, the remedy for this problem is simply to select strands of the same denier to be twisted together to the end that all colors of the twisted strands will be displayed equally in the yarn. However, in practice with textured strands this is not possible nor is it practicable to attempt to provide compensating means to correct for all the variable conditions. For example, when strands of the same denier are dyed in different dye lots, or are dyed with different types of dye, or dyed with different colors of dye the denier and coefficient of friction of the several strands will vary.

Furthermore, differing time, temperature, tension relationships during the dyeing process will also contribute to altering the denier of the several strands. Of equal importance, the variety of dyeing processes will also alter the frictional characteristics of the several strands for it is known that dyes will impart different coefficients of friction to yarn strands. Consequently, while the various strands may have been the same at the outset of processing their final deniers and coefficients of friction differ significantly. Thus, it will frequently occur that the denier relationship of the strands in each of several packages will vary from time to time throughout the package. Superimposed on this is the condition whereby the coefficient of friction of the strands are periodically altered, thus upsetting the tension imparted thereto by the tension devices. Therefore, as a multiplicity of packages are simultaneously unwound to deliver their ends for twisting together, one of the ends at some yarn section may be under lighter tension than the companion end. Since the strands are textured, relieving tension produces increasing denier. At another section conditions may change so that another one of the strands will be of the heaviest denier. Thus, in different linear yarn sections one color will dominate and at other times in other sections of the same yarn another color will dominate. When it is borne in mind that a prime objective of the described process is to furnish a variegated yarn capable of being used to produce a unformly mottled appearing fabric it can be appreciated that the conditions just described are in opposition thereto since such domination of one strand over' the others during twisting will inevitably lead to patterning in the fabric woven from the twisted yarn.

It is, therefore, one object of the present invention to provide method and apparatus for producing textured yarn comprised of several textured strands wherein the tension in each said strand is changed periodically to alter the effective denier of each of the strands during twisting.

Another object of the present invention is to provide apparatus capable of controlling the tension in multiple strands being twisted together, to thereby produce a yarn of uniform denier.

Yet, an additional object of the present invention is to provide apparatus for producing textured yarn comprised of several different strands twisted together wherein the effective denier of each strand is altered from time to time as the several strands are twisted together in order to exhibit each said strand uniformly in an end product formed from said yarn.

Another object of the present invention is to provide apparatus for producing textured yarn wherein the tension in each of the several strands comprising the yarn is altered randomly to alter the effective denier of one of the strands while the effective denier of the yarn being formed is maintained substantially constant.

A further object of the present invention is to provide apparatus for producing a yarn, which said apparatus is capable of incorporation in existing twisting machines.

Other objects of the invention will in part be obvious and will in part appear hereinafter.

For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawing wherein:

FIG. 1 is a fragmentary front elevation view of apparatus embodying the present invention;

FIG. 2 is a side elevational view, partly in section, of the structure of FIG. 1;

FIG. 3 is an enlarged front view of a tension device of the type employed in the apparatus of FIGS. 1 and 2; and

FIG. 4 is a side view of the tension device of FIG. 3.

Briefly, the present invention contemplates twisting a plurality of different, textured yarns together on a conventional twisting frame to form a textured yarn. Means are provided to alter the tension in each of the several strands, from time to time, so that at any given point along the length of yarn being formed some one strand will be of greater effective diameter than the adjacent twisted strands. The present invention provides means for altering randomly the particular strand which will be of greater effective diameter so that in a package of yarn each of the strands, at various length therealong, will be the strand of largest diameter. As a result, when the yarn is woven into a fabric the several constitutent strands of the yarn are exhibited substantially uniformly throughout the fabric. By this means, then, patterning is prevented in the woven fabric.

Turning now to the drawing, the apparatus illustrated in FIG. 1 includes two twisting stations or positions arranged in side-by-side relationship along a common frame, not illustrated. It will be appreciated that while the twisting positions may be arranged in any suitable number they will, in the usual commercial embodiment, be arranged in larger numbers than shown, spaced along the full length of the frame. The apparatus is provided with a plurality of creel pins ac supported on creel frame members 11. The creel pins each receive a yarn supply package P loosely thereon. A plurality of thread guide loops 12a-c and companion disc tensions 14a-c of a usual type are mounted on associated elongated bars 16a-c in alignment to receive a related one of the strands S being delivered off the supply packages P. Guide loops 12a-c and disc tensions 14a-c serve to guide the yarn in its flow from the packages and exert a light pre-tension to the strands to prevent inadvertent removal or run-off of the strands from the several packages as, for example, when the machine is stopped.

There are a pair of guide rods 18, 20 provided to extend the full length of the apparatus and supported in end brackets (not shown). Guide rods 18, 20 engage each strand in its downward flow and direct the strands each to a respective tension device 22a-c.

Each of the tension devices 22ac are supported from a support bar 24 which runs the entire length of the apparatus and is supported by suitable means, not herein illustrated, at the ends of the apparatus. As illustrated in FIG. 3 of the drawing each tension device 22a-c comprises two comb-like vanes 24, 26 between the alternate tines of which one of the strands S is passed. Vane 24 is swingable about a hinge pin 28 supported in a pair of spaced forwardly projecting lugs 30 of a supporting bracket plate 32. Vane 26 is fixedly supported between a further pair of spaced, forwardly projecting lugs 34 of bracket plate 32. The swingable vane 24 is connected by a tension spring 36 (see FIG. 4) to a vertical member 38 disposed parallel with and connected to plate 32. Said member 38 is located in a position spaced from plate 32 by screws 40, 42 threaded into the plate and projecting to engage with said vertical member. Rotation of screws 40, 42 permit adjustment of member 38 relative to plate 32 and, therefore, permit regulation of the force spring 36 on vane 24.

As best seen in FIG. 3 spring 36 is connected with vane 24 on one side of hinge pin 28. At the opposite side of vane 24 a laterally extending wing or tab 44 is provided. A further tension spring 46 is engaged in said tab and extends rearwardly to have its distal end connected to an adjustable element 48 connected with a rotatable collar 50 carried on a crank 52a of an elongated crank shaft 54 extending the length of the machine. Element 48 is adjustable to the end that the degree of expansion of spring 46 between vane 24 and the element 48 may be adjusted to thereby regulate the force of the spring on said vane 24.

Considering, now, in further detail the crank shaft 54 it will be seen from FIG. 1 that said crank shaft provides a separate crank 52a-f for each tension device. Moreover, viewing FIG. 2 it will be evident that the several cranks 52a-f are arranged in radial symmetry about the axis of crank shaft 54. However, the arrangement of cranks from twisting position to twisting position of the apparatus is desirably staggered so that angles at which the several different cranks diverge from the axis of crank shaft 54 do not coincide, as illustrated in FIG. 2. As will be related in more detail hereafter, this arrangement contributes further to precluding patterning in a fabric woven from the yarn.

Crank shaft 54 is rotatable so that the swingable vane 24 of each tension device may be operated to vary the tension in the strand engaged thereby. To this end a conventional electric motor 55 of the variable speed type is connected to an end of crank bar. Motor 55 is operable in any well known manner (not herein illustrated) to vary the rate at which crank shaft 54 is rotated in order that an irregular or variable rotational rate may be obtained therefrom for the crank shaft.

From the tension devices 22a-c the strands S are drawn downwardly through separate stop motion drop eyes 56a-c. From these drop eyes the several strands being twisted together at each twisting position are then threaded through a common yarn guide 58 and then engaged by a feed roll assembly 60. Stop motion drop eyes 5611-0 are of a conventional type known in the twisting art and supported on a frame member 62 extending along the length of the machine. The drop eyes 56a-c operate in the usual manner to interruptthe advance of the strands S at the associated twisting position in the event or breakage or runout of the strands passing therethrough.

Feed roll assembly 60 is also supported on an angle iron frame member 64 and, similarly, is a conventional type utilized in the yarn twisting art. The feed roll assembly includes a pair of rotatable feed rolls 66, 68 which are geared to a drive shaft 70 through clutch means, not shown. The strands S are wrapped about feed roll 66, 68 and as the rolls are driven the strands are advanced through the apparatus. The yarn leaving the feed rolls 66, 68 is passed over a stop motion roller 72 which operates to disengage the clutch means of the feed roll assembly 60 when the strands break.

A yarn guide 73 is provided to direct the yarn Y downward to conventional means for collecting the yarn Y from the feed roll assembly 60. Said conventional collecting means is operable to twist the strands S together to form yarn as the yarn is wound onto the take-up package. The collecting means includes a conventional twister spindle 74 supported in suitable bearing means (not shown) for rotation by driving means such a a belt (not illustrated). A traveler ring 76 is mounted for vertical reciprocation from end to end of bobbin B by reciprocating means not herein illustrated, but which is conventional in the twisting art. The usual traveler 78 is engaged with the traveler ring 76 to apply the desired tension to the yarn as it is fed by feed roll assembly 60 to bobbin B on spindle 74.

In operation of the apparatus the several supply strands S of textured yarn for each twisting position are threaded through the apparatus as already stated. That is to say, each strand S is drawn over the end of its package P, threaded through its respective one of the guide loops 12a-c and disc tensions 14a-c, drawn downward over rods 18, 20, threaded through its respective tension device 22a-f and drop eye 56a-c, engaged by feed roll assembly 60, and finally lead through traveler 76 and engaged on bobbin B.

As the apparatus is started the feed roll assembly 60 advances the strands S through the apparatus where they are twisted together in the zone between feed roll assembly 60 and bobbin B by rotation of traveler 76 to form yarn Y which is collected on bobbin B. Simultaneously with starting feed roll assembly 60 to advance the strands through the apparatus, variable speed motor 55 is started to rotate crank shaft 54. In consequence, the springs 46 of the tension devices are continuously expanded and relaxed by the motion of the cranks 5211-); Hence, the force of each spring 46 on its respective vane 24 is continuously varied resulting in a continually changing degree of interdigitation of the tines of the vanes 24 and 26. Therefore, the tension on each strand is continuously altered to the end that, at any given moment, some one strand has a lighter tension on it than the companion strands. Bearing in mind that the strands being processed are textured, the strand having lightest tension will be subjected to the least degree of elongation. Hence, this strand having the lightest tension thereon will exhibit the greatest effective denier as it is carried through feed roll assembly 60 and into the twisting zone between said assembly and bottom B. It follows that the strand of largest effective denier will be exhibited to the greatest degree in the yarn taken up on bobbin B. That is to say, the strand of largest or heaviest denier will occupy the greatest cross-sectional volume in the twist yarn. However, it is to be noted that all of the strands will be exhibited in every portion of the yarn, albeit to a lesser degree than the yarn having the heaviest effective denier. Since, each of the several strands, from time to time, is caused to be the strand of heaviest denier being twisted, and since this effect is randomized along the length of the yarn by virtue of the action of variable speed motor 55, the final yarn product randomly exhibits all of the strands, no one strand obliterating the appearance of adjacent strands completely, and no one strand dominating the appearance of the yarn for any extended length. It will be apparent that theextent to which one strand will be of the greatest effective denier, and therefore the dominant strand in a portion of the yarn, will be a function of the rotational speed of crankshaft 54. It will be apparent that the effective denier of the yarn being produced will be uniform over its full length notwithstanding that the denier of one or the other of the constituent strands is altered.

In the knitting weaving art it is usual to utilize the production of a single twisting apparatus for a single loom. Thus, the bobbins are dotted from the twisting apparatus and delivered as a lot to the loom. Possibly, then, two bobbins from the same apparatus could be fed to the Weaving or knitting unit simultaneously in such a fashion as to have the areas of the same dominant color in the yarns coincide. This, of course, will manifest itself in the woven or knitted fabric as areas of generally solid color interspersed with the further areas of mottled appearance. To the end that such condition may be forestalled, the present invention contemplates the arrangement whereby the cranks project a different angle from crankshaft 54, from twisting position to twisting position. Thus, viewing FIG. 2 it will be seen that the angular disposition of cranks 52ac (the cranks of the left-hand position of FIG. 1) do not coincide with the angles in which cranks 52d-f (the cranks of the right-hand position of FIG. 1) are arranged. Consequently, the initiation of operation of the tension devices from twisting position to twisting position is irregular. Therefore, the condition is precluded whereby yarns are made on the same apparatus at the same moment exhibiting the same color pattern. It follows that even if the two packages were used simultaneously in a further weaving process, and were started in use together, patterning would be forestalled in the fabric since the locations of the same types of dominant strands linearly along the yarn of the package would differ.

From the foregoing it will be readily evident that the present invention provides method and apparatus advantageously adapted to produce textured yarn from textured strands wherein the strands of the several packages at a given twisting position are randomly manipulated to provide a yarn exhibiting the characteristics of the several strands substantially even in a fabric woven therefrom.

Since certain changes may be made in the above method and apparatus without departing from the scope of the invention herein involved it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative only and not in a limiting sense.

What is claimed is:

1. Apparatus for producing yarn comprising, creel means for mounting a plurality of packages wound with textured strands, a twister spindle unit, a feed roll assembly for advancing said strands from said packages to said twister spindle unit, means for operating the twister spindle unit to twist said strands into a yarn, a tension device for tensioning each strand advancing to said twister spindle unit, and actuating means for operating said tension units to vary the tension imparted to each strand to change the deniers of said strands during twisting.

2. Apparatus as set forth in claim 1 wherein said actuating means includes crank means, said crank means serving to vary the tension output of each of said tension devices whereby a one of saidstrands has a less tension thereon than the remainder of said strands being twisted together, said crank means being operable to change the relative tension outputs of said tension devices to alter periodically the one of said strand having less tension thereon.

3. Apparatus as set forth in claim 1 wherein said actuating means is driven by a variable speed motor.

4. Apparatus as set forth in claim 2 including a resilient member connecting each said tension device with said crank means, and means for adjusting each said resilient member.

5. A method for producing yarn comprising the steps of, providing a plurality of textured strands from a supply source, advancing said strands from said supply source to a collecting means, continuously twisting together the strands being advanced to said collecting means, and continuously varying the tension in said strands prior to twisting thereof to change the deniers of said strands during twisting.

6. The method according to claim 5 including the steps of providing a different tension value to each said strand, and continuously altering the relative tension values in said strands.

References Cited UNITED STATES PATENTS 1,064,292 6/1913 Crawford 57-106 2,438,034 3/1948 Brugger 242-147 2,738,141 3/1956 Klein 57-1()6 2,882,675 4/1959 Tingas 57106 FRANK J. COHEN, Primary Examiner. W. H. SCHROEDER, Assistant Examiner. 

1. APPARATUS FOR PRODUCING YARN COMPRISING, CREEL MEANS FOR MOUNTING A PLURALITY OF PACKAGES WOUND WITH TEXTURED STRANDS, A TWISTER SPINDLE UNIT, A FEED ROLL ASSEMBLY FOR ADVANCING SAID STRANDS FROM SAID PACKAGES TO SAID TWISTER SPINDLE UNIT, MEANS FOR OPERATING THE TWISTER SPINDLE UNIT TO TWIST SAID STRANDS INTO A YARN, A TENSION DEVICE FOR TENSIONING EACH STRAND ADVANCING TO SAID TWISTER SPINDLE UNIT, AND ACTUATING MEANS FOR OPERATING SAID TENSION UNITS TO VARY THE TENSION IMPARTED TO EACH STRAND TO CHANGE THE DENIERS OF SAID STRANDS DURING TWISTING. 